Hugely popular Mozilla community providing support for Firefox, Thunderbird, Seamonkey and other well known Mozilla products. Over 350k members and 4 Million posts.
Discussion board for the massively popular xkcd web comic. Covering everything from Maths and Science to Logic Puzzles and Forum Games. Over 100k members and 2.4 Million posts.
OpenCart is popular, powerful, and easy to use shopping cart software. Their healthy community forums are powered by phpBB.
Zend Technologies is one of the largest and most popular companies producing a wide variety of tools and frameworks for PHP. Their community forums rely on phpBB.
Inspired by Max Berry's book, Jennifer Government, NationStates is one of the most popular online simulation games. The forum boasts over 5 million posts and 200,000 users.
KDE is mainly known for producing the KDE Desktop Environment (used in Kubuntu) for Linux.